Master-Slave Robot Controller Safety Signal Wiring
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Solution Overview
Problem
In robot systems with multiple controllers, simple wiring configurations for emergency stop operations often lead to reliability issues due to collisions among safety input signals, making it difficult to ensure the certainty of the safety input signal across all controllers.
Innovation Solution
A robot system configuration with a master controller and one or more slave controllers, where the master controller has two safety monitoring units to ensure the emergency stop operation based on a common safety input signal, and the slave controllers receive an enable signal from the master controller to perform the emergency stop, simplifying wiring and enhancing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If all controllers are connected to a single operating switch with simple wiring, then ease of operation is improved, but reliability deteriorates due to collisions among safety input signals
Solution Approach 1:
The patent divides the controllers into a master controller and slave controllers. The master controller receives the safety input signal directly from the operating switch, while slave controllers receive it through the master controller. This segmentation prevents signal collisions by establishing a hierarchical signal distribution structure where only the master controller directly processes the external safety signal.
Solution Approach 2:
The master controller acts as an intermediary between the operating switch and the slave controllers. It receives the safety input signal, processes it through its safety monitoring unit, and then distributes the processed signal to slave controllers. This intermediary role ensures that safety signals are properly managed and prevents collisions while maintaining system-wide emergency stop capability.
2Reliability
If each controller has its own safety monitoring function, then reliability is improved, but device complexity increases due to multiple safety input signal paths
Solution Approach 1:
The patent segments the safety monitoring function so that only the master controller performs the safety monitoring operation. Slave controllers rely on the master controller's safety monitoring results. This segmentation reduces device complexity by eliminating redundant safety monitoring hardware and wiring in slave controllers while maintaining reliability through the master controller's centralized safety management.
3Device complexity
If a single controller serves as main controller for safety signal distribution, then device complexity is reduced, but reliability deteriorates due to potential malfunction or connection abnormalities
Solution Approach 1:
The master controller performs preliminary safety monitoring and signal validation before distributing the safety signal to slave controllers. It checks the safety input signal's validity and only distributes it after confirmation. This preliminary action ensures that even in a simplified single-master configuration, reliability is maintained through proactive signal verification and error prevention.
Data Source
AI summary
In a robot system that is configured by a master controller and a slave controller, an input path of a safety input signal and an output path of an enable signal outputted from a safety monitoring unit within the master controller are wired to enable output outside of the master controller, an operating switch and the master controller are connected by a connection cable, the master controller and the slave controller are connected by a connection cable, a control unit of the slave controller is connected to the input path of the safety input signal, and a contact for power is connected to the output path of the enable signal.